Pre-fabricating a metal dormer

ABSTRACT

Pre-fabrication of a metal dormer provides for a one-step and relatively easy installation by a home owner, a roofing contractor or a carpenter. By using an aluminum alloy and specific forming and welding adaptations, a relatively water-tight, light and low-cost dormer may be readily pre-fabricated.

FIELD

The present application relates generally to fabrication of dormers and, more specifically, to a method for pre-fabricating a metal dormer.

BACKGROUND

A dormer is a structural element of a building that protrudes from the plane of a sloping roof surface. Dormers are used to create usable space in the roof of a building by adding headroom and usually also by enabling addition of windows. Dormers are also used as a secondary source of ventilation in attics when louver vents are installed therein, as opposed to windows.

Standard practice for Architectural Dormer fabrication involves constructing a dormer on-site from wood framing materials. Such construction is carried out to defined specifications and geometries within architectural drawings. Wood dormers can also be pre-fabricated, in a manner similar to the manner in which trusses are pre-fabricated, and lifted into place with a crane or extendable job boom fork lift.

Dormers for the home building industry are generally designed to meet various criteria. Dormers are designed to be weather tight to minimize ingress of wind, snow and rain. Dormers are also designed to withstand wind, water, snow and ice loads. Dormers are further designed to be aesthetically pleasing and to pass building code regulations.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made, by way of example, to the accompanying drawings which show example implementations; and in which:

FIG. 1 illustrates an example pre-fabricated dormer in an upper-front-left perspective view;

FIG. 2 illustrates the example pre-fabricated dormer of FIG. 1 in a lower-front-right perspective view;

FIG. 3 illustrates the example pre-fabricated dormer of FIG. 1 in a front plan view;

FIG. 4 illustrates the example pre-fabricated dormer of FIG. 1 in a left side view;

FIG. 5 illustrates example steps in a method of pre-fabricating a dormer such as the dormer of FIG. 1.

DETAILED DESCRIPTION

The present application relates to the pre-fabrication of an aluminum dormer with, for example, a sealed, ten-inch flange around the perimeter of the unit, thereby providing for a one-step and relatively easy installation by a home owner, a roofing contractor or a carpenter.

According to an aspect of the present disclosure, there is provided a method of pre-fabricating a dormer. The method includes forming, by press-brake and according to a planned geometry, a plurality of dormer components from a metal material, the forming creating creases, cutting the dormer components to fit a roof on which the dormer is to be installed, spot-welding to form welds between the dormer components, sealing between the welds and filling the creases with filling material.

Other aspects and features of the present disclosure will become apparent to those of ordinary skill in the art upon review of the following description of specific implementations of the disclosure in conjunction with the accompanying figures.

FIG. 1 illustrates an example pre-fabricated dormer 100 in an upper-front-left perspective view. The dormer 100 includes a base plate 102 to which a dormer structure 104 is attached.

The dormer structure 104 includes several components, named herein as a dormer roof 104A, a dormer left wall 104BL and a dormer right wall 104BR. At a seam between the dormer left wall 104BL and the dormer roof 104A, the dormer structure 104 includes a left cap 104CL. At a seam between the dormer right wall 104BL and the dormer roof 104A, the dormer structure 104 includes a right cap 104CR. The dormer structure 104 further includes a primary internal frame 106A and secondary internal frame 106B. The primary internal frame 106A and the secondary internal frame 106B are shaped to match an internal shape of the combination of the dormer right wall 104BR, the dormer left wall 104BL and the dormer roof 104A.

The person of ordinary skill in the art will understand that many ornamental shapes are available for the dormer walls 104BR, 104BL and the dormer roof 104A. The dormer roof 104A, as illustrated in FIG. 1 has a semi-circular (arcuate) cross-section.

FIG. 2 illustrates the example pre-fabricated dormer 100 of FIG. 1 in a lower-front-right perspective view.

FIG. 3 illustrates the example pre-fabricated dormer 100 of FIG. 1 in a front plan view.

FIG. 4 illustrates the example pre-fabricated dormer 100 of FIG. 1 in a left side view.

The applicant has found that, for certain dimensions, forming the dormer roof 104A and the dormer walls 104BR, 104BL of 16 Ga (0.0571 inches thick) 5083 Aluminum alloy presented difficulties when such forming was attempted using common methods.

The known 5083 Aluminum alloy was selected for reduced weight, relative to wood, and to provide a predictable degree of corrosion resistance. It has also been contemplated that an alternative material, the known 6061-T6 Aluminum alloy, may be used.

Conveniently, the Applicant has developed a method of pre-fabricating metal dormers that overcome various difficulties associated with geometry and metal materials.

FIG. 5 illustrates example steps in a method of pre-fabricating a metal dormer, such as the dormer 100 of FIG. 1.

Initially, the aluminum is etched (step 502) to show the lines along which cuts will be made following the forming step. In the case of the dormer 100 of FIG. 1, eight components are to be cut and five of these components are to be formed. The five components include: the dormer roof 104A, the dormer left wall 104BL; the dormer right wall 104BR, the left cap 104CL, and the right cap 104CR.

The five components are then formed (step 504) to match a desired geometry. For example, a press-brake process may be used in the forming (step 504). The Applicant has noted spaces between press-brake creases and these creases are dealt with in a later step.

Each of the components are then cut (step 506), according to desired geometry, to fit the slope of the roof on which the dormer 100 will be installed. The cutting (step 506) may, for example, be accomplished using plasma technologies. The cutting (step 506) may, for example, be carried out in a manner that allows the dormer 100 to fit a 38-degree angle for a roof with 9.25:12 pitch. The cutting (step 506) may, for another example, be carried out in a manner that allows the dormer 100 to fit a 45-degree angle for a roof with a 12:12 pitch.

The components are then welded (step 508) together to arrive at the desired design for the dormer 100. The Applicant has found spot-welding suitable for step 508. However, the Applicant has also found that spot-welding results in a dormer that is not particularly water-tight. The non-water-tight welds are dealt with in the next step.

It is known that spot-welding leaves gaps between spot-weld locations. Each of these gaps between the spot-weld locations created in step 508 are then sealed (step 510) to comply with parameters that set out the degree to which the dormer 100 is to be weather-tight. In one example, the gaps between spot-weld locations may be sealed (step 510) with caulking. Additionally, voids and cavities between the press-brake creases are filled (step 510) with filler material. One material deemed suitable for use as the filler material in step 510 is Titanium Putty from ITW Devcon, which is a division of Illinois Tool Works of Glenview, Ill. As is conventional, once the filling material has cured, the filling material may be sanded to result in a relatively smooth surface. That is, a surface with minimal evidence of creases, dimples or blemishes.

In aesthetic-related processing, the dormer 100 may be anodized, etched and/or sandblasted. Furthermore, the dormer 100 may be powder coated to a desired colour. For example, the desired color may match to siding, windows, soffit and/or fascia. The process in general is called “Pre-Treatment Wash”. The aesthetic-related processing may, for example, begin with a light sandblasting with virgin material (new sand product) followed by an acid wash. The dormer may then be left to dry. Powder coating is the final stage of the aesthetic-related processing.

The completed dormer 100 is installed by screwing the base plate 102 onto the roof. The installation may be accomplished with, for example, zinc-plated screws every linear 12″ distance about 10″ in from the outer perimeter of the base plate 102. As will be understood, the dormer 100 may also be installed by securing the dormer 100 to wood framing with nails or other mechanical fastening means.

Conveniently, a pre-fabricated dormer 100 constructed from aluminum materials may be noted for being relatively light compared to heavier wood. In one example, the total weight of the aluminum dormer 100 is 45 lbs. Furthermore, a pre-fabricated dormer 100 constructed from aluminum materials may be noted for being relatively low-cost relative to specialty metal dormers.

The above-described implementations of the present application are intended to be examples only. Alterations, modifications and variations may be effected to the particular implementations by those skilled in the art without departing from the scope of the application, which is defined by the claims appended hereto. 

What is claimed is:
 1. A method of pre-fabricating a dormer, the method comprising: forming, by press-brake and according to a planned geometry, a plurality of dormer components from a metal material, the forming creating creases; cutting the dormer components to fit a roof on which the dormer is to be installed; spot-welding to form welds between the dormer components; sealing between the welds; and filling the creases with filling material.
 2. The method of claim 1 further comprising etching the metal material to show lines along which the cutting will occur.
 3. The method of claim 1 wherein the metal material comprises 5083 Aluminum alloy.
 4. The method of claim 1 wherein the metal material comprises 6061-T6 Aluminum alloy.
 5. The method of claim 1 wherein the filling material comprises Titanium Putty.
 6. The method of claim 1 further comprising sanding the filing material.
 7. The method of claim 1 further comprising anodizing the dormer.
 8. The method of claim 1 further comprising sandblasting the dormer.
 9. The method of claim 1 further comprising powder coating the dormer to a desired colour.
 10. The method of claim 1 wherein the forming creates dimples and the method further comprises filling the dimples with filling material.
 11. The method of claim 1 wherein the roof has a 9.25:12 pitch.
 12. The method of claim 1 wherein the roof has a 12:12 pitch.
 13. The method of claim 1 further comprising etching the dormer.
 14. The method of claim 1 further comprising anodizing the dormer.
 15. The method of claim 1 wherein the sealing between the spot-weld locations comprises caulking between the spot-weld locations.
 16. A dormer pre-fabricated by: forming, by press-brake and according to a planned geometry, a plurality of dormer components from a metal material, the forming creating creases; cutting the dormer components to fit a roof on which the dormer is to be installed; spot-welding to form welds between the dormer components; sealing between the welds; and filling the creases with filling material. 